6.0 Litros Cylinder Head Rh

303-01C-1 303-01C-1Engine — 6.0L Diesel

IN-VEHICLE REPAIRRemovalCylinder Head — RH

All vehiclesSpecial Tool(s)

Lifting Bracket, Cylinder Head1. With the vehicle in NEUTRAL, position it on a303-759

hoist. For additional information, refer toSection 100-02.

2. Drain the engine oil.

3. Remove the intake manifold. For additionalHeavy Duty Floor Crane information, refer to Intake Manifold in this014-00071

section.

4. Remove the evaporator core housing. Foradditional information, refer to Section 412-02.

5. NOTE: Only one retainer shown.Release Tool, Injector Disconnect the wiring retainers from the studs.Connector303-1115

Remove/Installer, Glow PlugConnector303-1114

Material Late buildItem Specification

SAE 15W-40 Super Duty WSS-M2C171-B 6. Remove the injection control pressure (ICP)Motor Oil sensor.XO-15W40-QSD orequivalent

High Temperature Nickel ESE-M12A4-AAnti-Sieze LubricantXL-2 or equivalent

Metal Brake Parts Cleaner —PM-4 (Canada CPM-4)

Copyright 2003, Ford Motor CompanyLast updated: 05/24/2003 2004 Excursion, F-Super Duty 250-550, 12/2004


IN-VEHICLE REPAIR (Continued)

All vehicles

7. If equipped, remove the nut and position thetransmission fluid and indicator aside.

Two-piece head tube

10. NOTE: Some engines may have been updatedwith a new two-piece crankcase-to-head tube. Ifthe crankcase-to-head tube has been updated it

8. NOTE: Late build shown, early build similar. will have a hex head.

NOTE: Mark the position of the valve cover If the high-pressure oil rail has a hex head,bolts for the valve cover bolt installation. remove the crankcase-to-head tube assembly.

Remove the bolts and the valve cover. • Remove and discard the O-ring seals.

• Clean and inspect the valve cover gasket.Install a new gasket if necessary.

Late build

9. Remove the high-pressure oil rail-to-valve covergasket.

2004 Excursion, F-Super Duty 250-550, 12/2004



Late build

11. NOTE: Do not remove the oil rail end plugs oracoustic wave attenuator port fitting. Serviceparts are not available to support thecomponents.

Remove the bolts and the high-pressure oil rail.

14. Remove the bolts and the high-pressure oil rail.

Two-piece head tube

12. CAUTION: Use care not to deform thelower crankcase-to-head tube duringremoval. If the tube is damaged, a new tubemust be installed.

15. Disconnect and remove the high-pressure oilNOTE: Use a shop towel and metal brake partssupply line.cleaner to remove the oil residue prior to

removing.

If the updated crankcase-to-head tube separated,using a pair of soft jawed pliers, remove thelower crankcase-to-head tube.

Early build

13. Disconnect the high-pressure oil rail supply lineat the high-pressure oil rail.




All vehicles

16. CAUTION: Do not attempt to applybattery voltage to the fuel injector or damageto the fuel injector will occur.

Using the special tool, push the fuel injectorelectrical connector out of the rocker armcarrier.

19. NOTE: If a snap ring or piece of a snap ring ismissing from the injector hold-down assembly,it must be located prior to removing the shop.

Remove the shop towels.

20. Remove the starter. For additional information,refer to Section 303-06B.

21. Remove the cylinder drain block.

17. Prior to removing the fuel injector assembly,insert clean shop towels in the oil drain holesadjacent to each glow plug.

18. CAUTION: Failure to account for allsnap rings or pieces prior to placing thevehicle back in service can cause enginedamage. A missing snap ring can be ingestedinto the lube oil system, causing severeengine damage.

CAUTION: To prevent engine damage,do not use air tools to remove the fuelinjectors. The snap ring that extracts the

22. NOTE: LH shown, RH similar.injector can dislodge and fall into the oilRemove the nuts and bolts from thedrain hole.turbocharger adapter pipe.NOTE: There is no need to drain the fuel rail.

NOTE: If engine coolant is found in thecombustion chambers, it may be necessary toinstall a new injector sleeve. For additionalinformation, refer to Section 303-04C.

Remove the bolt, fuel injector hold-down clampand fuel injector.




One-piece head tube23. Remove the turbocharger adapter pipe.

NOTE: The rings on the crankcase-to-head tube areto be used to pry the tube assembly from the branchtube assembly or the oil rail assembly.

26. Remove the crankcase-to-head tube assembly.

• Remove and discard the O-rings.

Early build

24. Remove and discard the crankcase to head tubeassembly.

Late build

27. CAUTION: Do not pull on the wiringto remove the glow plug connector ordamage may occur.

NOTE: Only one glow plug connector shown.

Using the special tool, remove the glow plugharness.

25. Remove the glow plug buss bar.




All vehicles

28. Remove the four glow plugs.

32. CAUTION: To prevent engine damage,keep the push rods in the order in whichthey were removed. Install all push rodsback in their original positions.

29. Remove and discard the 10 inner cylinder head Mark the location and remove the eight pushbolts. rods.

30. Remove the eight bolts and the rocker arm 33. Remove the outer cylinder head bolts.assemblies.

31. Mark the eight valve bridges with a permanentmarker and remove.




Installation34. Install the special tool and the lifting crane.With the help of an assistant, remove thecylinder head from the vehicle. One-piece head tube

1. CAUTION: Install new D-ring seals onthe crankcase-to-head tube. It requiresseveral hours after installation for the D-ringseals to relax back to their original size. Ifthe tube assembly is installed before theD-ring seals have relaxed, damage to theD-ring seals can occur.

Install new D-ring seals on each end of thecrankcase to head tube assemblies.

35. Check for cylinder head distortion. Foradditional information, refer to Cylinder HeadDistortion in this section.

36. Remove and discard the cylinder head gasketand dowels.

• Clean and inspect the gasket sealingsurfaces.

Two-piece head tube

2. CAUTION: Install new D-ring seals onthe crankcase-to-head tube. It requiresseveral hours after installation for the D-ringseals to relax back to their original size. Ifthe tube assembly is installed before theD-rings have relaxed, damage to the D-ringseals can occur.

Install new D-ring seals on thecrankcase-to-head tube.




All vehicles 6. CAUTION: To prevent engine damage,keep the push rods in the order in which

3. NOTE: Use care to avoid scratching the blue they were removed. Install all push rodscompound on the cylinder head gasket. Install a back in their original positions.new cylinder head gasket with the part number NOTE: Higher mileage engines require pushfacing up and verify the top five holes and the rods to be cleaned so the copper colored end ofhead gasket push rod holes line up. the push rod can be identified.Install the dowels and the cylinder head gasket. NOTE: If a push rod has been replaced, it may

not have a copper-colored end and can be4. Using the special tools and with the help of an installed with either end up.

assistant, install the cylinder head on theApply clean engine oil to each end of the pushengine. Remove the special tools.rods. Insert them into their respective positionswith the copper colored end up.

5. Install the outer cylinder head bolts finger-tight.

7. NOTE: Coat the end of each valve stem withclean engine oil.

Install the eight valve bridges.




8. CAUTION: Rotate the crankshaft untilthe damper locating dowel notch is in the sixo’clock position or engine damage can occur.

NOTE: Apply clean engine oil to the top centerof each valve bridge.

Install the rocker arm assemblies and eightbolts.

10. Tighten the head bolts in the followingsequence.

1 Tighten bolts 1 through 10 to 88 Nm (65lb-ft).

2 Tighten bolts 1 through 10 to 115 Nm (85lb-ft).

3 Tighten bolts in sequence 1 through 10,clockwise 90 degrees.

9. CAUTION: Using too much engine oil 4 Tighten bolts in sequence 1 through 10, aon the threads of the cylinder head bolts can second time, clockwise 90 degrees.cause damage to the threads and poor

5 Tighten bolts in sequence 1 through 10, asealing. Using anti-seize compounds, greasethird time, clockwise 90 degrees.or any other lubricants other than engine oil

6 Tighten bolts 11 through 15 to 24 Nm (18on the cylinder head bolt threads can affectlb-ft).the true torque value of the bolts.

7 Tighten bolts 11 through 15 to 31 Nm (23NOTE: Lightly lubricate the new cylinder headlb-ft).bolt threads and flanges with clean engine oil.

Install the 10 new inner cylinder head retainingbolts finger-tight.




11. Install the four glow plugs.

Early build

Late build 14. NOTE: Clean and inspect the glow plug bussbar O-rings and install new as necessary.

12. NOTE: Clean and apply clean engine oil to the NOTE: Apply clean engine oil to the O-ringsO-rings. before installing.Using the special tool, install the glow plug Install the glow plug buss bar.harness.

15. NOTE: Install a new lower O-ring.One-piece head tubeInstall a new crankcase to head tube assembly.

13. CAUTION: To prevent engine damage,check that the crankcase-to-head tubeassemblies bottom out in the branch tubeassembly. The oil rail, crankcase-to-headtube and the fuel injectors will not functioncorrectly if the tube is not bottomed out.

Apply clean engine oil and install thecrankcase-to-head tube assembly.




All vehicles 19. Install the starter. For additional information,refer to Section 303-06B.

16. Position the turbocharger adapter pipe.20. CAUTION: If the fuel injector oil inlet

D-shaped O-ring seal is damaged, a new fuelinjector must be installed.

Install new O-rings seals and copper washer onthe fuel injector. Lubricate the fuel injector andO-ring seals liberally with clean engine oil.

17. NOTE: Apply anti-seize lubricants to the boltthreads prior to installing the bolts.

NOTE: Do not tighten until after theturbocharger is installed.

Install the nuts and bolts in the adapter pipe.

21. CAUTION: Failure to tighten theinjector properly can lead to engine failure.

CAUTION: To prevent engine damage,do not use air tools to install the fuelinjectors. The snap ring that extracts theinjector can dislodge and fall into the oildrain hole.

Install the fuel injector, fuel injector hold-downclamp and bolt.

18. NOTE: Apply clean engine oil to the O-ringprior to installing.

Install the cylinder block drain plug.




Late build22. CAUTION: Make sure the injectorwiring is clear of all moving parts or engine

24. NOTE: Apply clean engine oil to the top fueldamage can occur.injector D-ring before installing the highInstall the fuel injector electrical connector intopressure oil rail.the rocker arm carrier.Position the oil rail on the fuel injectors.

• Place the oil rail on top of the carrier sothat the four single ball tubes are engagingthe injector lead angle.

• Insert three guide bolts, two on the ends ofthe straight side of the oil rail and one inthe middle of the wavy side of the oil rail.Install the guide studs six to seven turns.

• Press the oil rail into the fuel injectors.

• Inspect that the oil rail mounting feet areflat against the mounting surface.

• Loosely install the six bolts.

23. Apply engine oil to the top fuel injector O-ringseals.

25. Install the oil rail retaining bolts.

• Remove the three guide bolts.

• Loosely install the three remaining bolts.

• Tighten the bolts in the sequence shown.




Two-piece head tube

26. NOTE: Apply clean engine oil to thecrankcase-to-head tube prior to installation.

If equipped with an updated crankcase-to-headtube, install the crankcase-to-head tubeassembly.

29. Tighten the bolts in the sequence shown.

Late build

27. Install the high-pressure oil rail-to-valve covergasket.

30. Install the high-pressure oil line.

Early build

28. Install the high-pressure oil rail and bolts.

• Install the high-pressure oil rail.

• Install the bolts finger tight.




All vehicles

NOTE: Late build shown, early build similar.

31. CAUTION: To prevent engine damage,do not use air-powered tools when installingthe valve cover.

Position the valve cover gasket. Install thevalve cover and 11 bolts.

All vehicles

34. NOTE: Only one retainer shown.

Connect the wiring retainers to the studs.

32. If equipped, position back the transmission fluidindicator and tube. Install the retaining nut.

35. Install the evaporator core housing. Foradditional information, refer to Section 412-02.

36. Install the intake manifold. For additionalinformation, refer to Intake Manifold in thissection.

37. NOTE: Install a new oil filter.Late build Fill the crankcase with clean engine oil.

33. Install the ICP sensor.


6.0 Litros Cylinder Head Rh

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